System and method for determining and controlling focal distance in a vision system camera

ABSTRACT

This invention provides a system and method for determining and controlling focal distance in a lens assembly of a vision system camera using an integral calibration assembly that provides the camera&#39;s image sensor with optical information that is relative to focal distance while enabling runtime images of a scene to be acquired along the image axis. The lens assembly includes a variable lens located along an optical axis that provides a variable focus setting. The calibration assembly generates a projected pattern of light that variably projects upon the camera sensor based upon the focus setting of the variable lens. That is, the appearance and/or position of the pattern varies based upon the focus setting of the variable lens. This enables a focus process to determine the current focal length of the lens assembly based upon predetermined calibration information stored in association with a vision system processor running the focus process.

This application is a continuation of U.S. patent application Ser. No.13/563,499, titled “System and Method for Determining and ControllingFocal Distance in a Vision System Camera,” filed on Jul. 31, 2012, theentire contents of which is incorporated herein by reference.

FIELD OF THE INVENTION

This invention relates to automatic focusing systems for camera lensesand more particularly to automatic focusing lens systems in visionsystem cameras employing liquid lens assemblies.

BACKGROUND OF THE INVENTION

Vision systems that perform measurement, inspection, alignment ofobjects and/or decoding of symbology (e.g. bar codes) are used in a widerange of applications and industries. These systems are based around theuse of an image sensor, which acquires images (typically grayscale orcolor, and in one, two or three dimensions) of the subject or object,and processes these acquired images using an on-board or interconnectedvision system processor. The processor generally includes bothprocessing hardware and non-transitory computer-readable programinstructions that perform one or more vision system processes togenerate a desired output based upon the image's processed information.This image information is typically provided within an array of imagepixels each having various colors and/or intensities. In the example ofa symbology (barcode) reader, the user or automated process acquires animage of an object that is believed to contain one or more barcodes. Theimage is processed to identify barcode features, which are then decodedby a decoding process and/or processor obtain the inherent alphanumericdata represented by the code.

Often, a vision system camera includes an internal processor and othercomponents that allow it to act as a standalone unit, providing adesired output data (e.g. decoded symbol information) to a downstreamprocess, such as an inventory tracking computer system. It is desirablethat the camera assembly contain a lens mount, such as the commonly usedC-mount, that is capable of receiving a variety of lens configurationsso that it can be adapted to the specific vision system task. The choiceof lens configuration can be driven by a variety of factors driven bysuch factors as lighting/illumination, field of view, focal distance,relative angle of the camera axis and imaged surface, and the finenessof details on the imaged surface. In addition, the cost of the lensand/or the available space for mounting the vision system can also drivethe choice of lens.

An exemplary lens configuration that can be desirable in certain visionsystem applications is the automatic focusing (auto-focus) assembly. Byway of example, an auto-focus lens can be facilitated by a so-calledliquid lens assembly. One form of liquid lens uses two iso-densityliquids—oil is an insulator while water is a conductor. The variation ofvoltage passed through the lens by surrounding circuitry leads to achange of curvature of the liquid-liquid interface, which in turn leadsto a change of the focal length of the lens. Some significant advantagesin the use of a liquid lens are the lens' ruggedness (it is free ofmechanical moving parts), its fast response times, its relatively goodoptical quality, and its low power consumption and size. The use of aliquid lens can desirably simplify installation, setup and maintenanceof the vision system by eliminating the need to manually touch the lens.Relative to other autofocus mechanisms, the liquid lens has extremelyfast response times. It is also ideal for applications with readingdistances that change from object-to-object (surface-to-surface) orduring the changeover from the reading of one object to another object.

A recent development in liquid lens technology is available fromOptotune AG of Switzerland. This lens utilizes a movable membranecovering a liquid reservoir to vary its focal distance. This lensadvantageously provides a larger aperture than competing designs andoperates faster. However, due to thermal drift and other factors, theliquid lens may lose calibration and focus over time.

One approach to refocusing a lens after loss of calibration/focus is todrive the lens incrementally to various focal positions and measure thesharpness of an object, such as a runtime object or calibration target.However, this requires time and effort that takes away from runtimeoperation, and can be an unreliable technique (depending in part on thequality of illumination and contrast of the imaged scene).

It is therefore desirable to provide a system and method for stabilizingthe focus of a liquid (or other auto-focusing) lens type that can beemployed quickly and at any time during camera operation. This systemand method should allow a lens assembly that mounts in a conventionalcamera base mount and should avoid and significant loss of performancein carrying out vision system tasks. The system and method should allowfor focus over a relatively wide range (for example 20 cm to 2 m) ofreading distance.

SUMMARY OF THE INVENTION

This invention overcomes disadvantages of the prior art by providing asystem and method for determining and controlling focal distance in alens assembly of a vision system camera using an integral calibrationassembly that provides the camera's image sensor with opticalinformation that is relative to focal distance while enabling runtimeimages of a scene to be acquired along the image axis. In anillustrative embodiment, a system and method for determining focaldistance of a lens assembly includes a variable lens located along anoptical axis of the lens assembly that provides a variable focussetting. This variable lens can be associated with a fixed imager lenspositioned along the optical axis between the variable lens and a camerasensor. A novel calibration assembly integral with the lens assembly isprovided. The calibration assembly generates a projected pattern oflight that variably projects upon the camera sensor based upon the focussetting of the variable lens. That is, the appearance and/or position ofthe pattern varies based upon the focus setting of the variable lens.This enables a focus process to determine the current focal length ofthe lens assembly based upon predetermined calibration informationstored in association with a vision system processor running the focusprocess. The calibration assembly can be located along a side of thelens so as to project the pattern of light from an orthogonal axisapproximately perpendicular to the optical axis through a reflectingsurface onto the optical axis. This reflecting surface can comprise aprism, mirror and/or beam splitter that covers all or a portion of thefiled of view of the lens assembly with respect to an object on theoptical axis. The pattern can be located on a calibration target that islocated along the orthogonal axis and is remote from the reflectingsurface.

Illustratively, the calibration target can define alternatingtransparent and opaque regions and can be illuminated (e.g. backlit byan LED illuminator). This target is illustratively oriented along anacute slant angle with respect to a plane perpendicular to theorthogonal axis so that pattern elements of the target (e.g. parallellines) are each associated with a predetermined focal distance. For agiven focal distance, the sharpness of a plurality of adjacent linepairs is evaluated. The sharpest pair represents the current focaldistance. An intervening calibration assembly lens can resolve the lightrays from the calibration target before they strike the beam splitter soas to provide the desired range of focal distances at the sensor (e.g.20 cm-2 m (or infinity)). Illustratively the target can be illuminatedby light of a predetermined wavelength (visible or non-visible), and thefocus process distinguishes the predetermined wavelength so thatcalibration can potentially run without interfering with regular runtimeimaging of objects.

In another embodiment, the calibration assembly can include a projected“pattern” defined generally as a spherical wave front. The lens assemblyincludes at least one micro lens, and generally a plurality of microlenses each defining a portion of a wave front sensor that is orientedto project the pattern onto a predetermined portion of the camerasensor. Typically this portion is near an outer edge of the sensor sothat it minimally interferes with the field of view used for runtimeimage acquisition.

The system and method can further include, within the focus process, acontrol process that controls and/or adjusts the focus setting of thevariable lens based upon the determined focal distance and a desiredfocal distance for the lens assembly. The variable lens can be a liquidlens, or other movable geometry lens, and more particularly can comprisea membrane-based liquid lens.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention description below refers to the accompanying drawings, ofwhich:

FIG. 1 is a schematic perspective view of a vision system cameraincluding a lens arrangement for determination and control of focaldistance according to an embodiment herein, shown acquiring images of anobject in a scene;

FIG. 2 is a schematic diagram of a lens arrangement according to anembodiment herein including a membrane-based liquid lens and a fixedimager lens oriented along an optical axis between an object and acamera image sensor;

FIG. 3 is a schematic diagram of a lens arrangement as shown in FIG. 2oriented between an object and an image sensor, and including acalibration assembly based upon a slanted calibration target accordingto an illustrative embodiment;

FIG. 3A is a schematic diagram of an idealized representation of theoptical system of FIG. 3 showing the computation of focal distance ofthe liquid lens therein;

FIGS. 3B and 3C are schematic diagrams of the ray trace of the opticalsystem of FIG. 3 shown for the variable lens at minimum (approximatelyzero) and maximum optical power, respectively;

FIG. 4 is a schematic diagram of a lens arrangement as shown in FIG. 2oriented between an object and an image sensor, and including acalibration assembly based upon an illumination point source andShack-Hartmann (wave front) sensor according to an illustrativeembodiment;

FIGS. 4A and 4B are a schematic diagrams illustrating the computation ofthe focal distance of the variable lens according to the illustrativeShack-Hartmann embodiment of FIG. 4;

FIG. 5 is a schematic diagram of a lens arrangement as shown in FIG. 2oriented between an object and an image sensor, and including acalibration assembly based upon redirection of part of the field of viewto an integral calibration target according to an illustrativeembodiment; and

FIG. 6 is a flow diagram of an illustrative procedure for determiningand controlling focal distance in a camera assembly including a variablelens and a calibration assembly according to at one of the arrangementsof FIGS. 3-5.

DETAILED DESCRIPTION

FIG. 1 shows a vision system arrangement 100 according to anillustrative embodiment. The arrangement 100 includes a vision system,camera 110 having a camera body 112 that mounts a lens assembly 114. Thelens assembly 114 is part of an optical package that also includes aninternal image sensor 116 (shown in phantom) within the body 112. Thesensor and lens are aligned along an optical axis OA as shown, with thesensor defining a perpendicular focal plane with respect to the axis OA.The axis OA is shown passing approximately through an exemplary featureof interest 120 (e.g. a barcode) on an object 122. The feature 120resides within a field of view (dashed box 124) that can vary in sizedepending upon the vision system task. The size of the field of view is,in part dependent upon the reading/viewing distance D between the object122 and the focal point of the lens assembly 114. In this embodiment,the lens assembly 114 includes a pair of lenses L1 and L2 (both shown inphantom and described in detail below) that focus light from the imagedscene onto the sensor 116. The sensor transmits captured image data to avision processor 140 (also shown in phantom) that performs vision systemprocesses on the image data (e.g. ID finding, alignment, inspection,etc.) based upon programmed vision system tools and processes, andoutputs desired image information 150 that can be used in downstreamprocesses and applications, such as ID decoding and handling. Theprocessor 140 can be entirely self-contained within the camera body 112,partially contained within the body, or external to the body—such as astandalone computer (e.g. a PC) or other remote computing device.Appropriate wired and/or wireless communication links are providedbetween the sensor assembly 116 processor 140 and other downstreamimage-data-processing and/or image-data-handling components. Theprocessor can also control other typical functions such as internal orexternal illumination (not shown), triggering, etc.

As used herein the terms “process” and/or “processor” should be takenbroadly to include a variety of electronic hardware and/or softwarebased functions and components. Moreover, a depicted process orprocessor can be combined with other processes and/or processors ordivided into various sub-processes or processors. Such sub-processesand/or sub-processors can be variously combined according to embodimentsherein. Likewise, it is expressly contemplated that any function,process and/or processor here herein can be implemented using electronichardware, software consisting of a non-transitory computer-readablemedium of program instructions, or a combination of hardware andsoftware.

With reference to the schematic diagram of FIG. 2, the arrangement oflenses L1 and L2 with respect to the object field of view 124 and theexposed area of the sensor 116 is shown in further detail. Each of thecomponents is aligned with the optical axis OA as shown, the sensor 116being perpendicular thereto, and forming an image plane. In thisillustrative arrangement, a rear, fixed imager lens (e.g. a convex lens)L1, typically of conventional design is provided to focus the image(rays 210, 212) on the sensor 116. In addition, a frontvariable-geometry (or “variable”) lens L2 is provided. In an embodiment,this lens can comprise the above-described membrane-based liquid lensarrangement (i.e. the Optotune membrane-based liquid lens). The focallength/distance of the optical system can be varied within apredetermined range (e.g. 20 cm-to-2 m (or infinity)) based upon thesetting of the variable lens L2. This setting is varied by applyingforce (F) to the perimeter of the membrane using, for exampleelectromagnetic actuation in accordance with known and/or commerciallyavailable techniques.

Because certain variable lens types, such as the above-describedmembrane-based liquid lens can lose calibration of focal distance overtime, and more generally because it is desirable to maintain goodcalibration, the ability to quickly and automatically determine andcontrol focal distance is highly desirable. The use of an externalcalibration target is not always practical in a runtime environment andcan be time-consuming. Alternatively, relying upon acquired images ofruntime objects to estimate focal distance can be unreliable and ispotentially degraded by inadequate illumination and other variableswithin the runtime environment. Thus, in accordance with embodimentsherein, an integral calibration assembly is provided. This assemblypresents a reliable and consistent calibration target (or otherfiducial(s)) to the sensor so that focal distance can be continuouslydetermined and updated as desired.

Reference is made to FIG. 3, which shows a schematic diagram of anillustrative embodiment of a lens assembly 300. The lenses L1 and L2(described above, with reference to FIG. 2) are unchanged and residealong the optical axis OA between the sensor 116 and the object 124. Acalibration assembly 310 is provided along an axis CA that isperpendicular to the optical axis OA. The calibration assembly axis CAintersects the optical axis at a point 312 in proximity to the front ofthe variable lens L2 at a 45-degree mirror (i.e. a beam splitter) 314that reflects light from the calibration assembly 310 onto the opticalaxis OA to the sensor 116, and also allows light from the object 124 topass along the optical axis OA to the sensor 116. The calibrationassembly 310 includes a convex (or other type) of fixed lens L3 thatfocuses light from an illuminator 320, such as an LED assembly ofpredetermined wavelength. This wavelength is highly variable and can bein the visible spectrum or invisible, near infrared (IR). The light fromthe illuminator passes through a transparent calibration plate 330 thatcan define alternating transparent/translucent and opaque (e.g. black),parallel lines (or another pattern). The calibration plate 330 isslanted at an acute angle α with respect to the perpendicular plane 332passing through the axis CA. The slant angle α of the target is highlyvariable, and generally defines a furthest position 340 from the lens L3on one end and a closest position 342 on the opposing end thereof. In anembodiment, the angle α is chosen so that, in combination with the lensL3, each parallel, each opaque line represents a different, known focaldistance ranging from approximately 20 cm to infinity (by way ofexample). In an embodiment, the distance D1 of the furthest position 340of the target 330 from the lens L3 and can represent a focal distance ofinfinity. As shown a discrete position and associated line can be set toa focal distance of (for example) 1 m. The processor (140) executes afocus process (160 in FIG. 1) to locate this line and/or a line that isin best focus. The system can include stored calibration data (170 inFIG. 1) containing, for example, the known focal distance for each linein the target 330. This data can be arranged, for example as a look-uptable that matches lines with predetermined focal distance values and/orinformation. Based upon this information, the process determines thelens assembly's state of focus using known techniques. The lens L2 isadjusted by the focus process 160 (as described further below) basedupon computations for focusing at the exemplary, desired focal distance(e.g. 1 m).

Because the light output from the illuminator 320 can be setsignificantly higher than the ambient light received by the lensassembly 300 from the object, the projected pattern of target 330 can bedifferentiated by the sensor 116 when the illuminator is activated (i.e.during a calibration step that can occur between runtime imageacquisition steps). Alternatively, the light from the illuminator 320can be differentiated using a discrete wavelength and/or a non-visiblewavelength (e.g. IR) that the sensor is adapted to associate with thecalibration target 330. When the illuminator is deactivated duringruntime, the sensor reads only ambient light from the object 124.Alternatively, the mirror 314 can be arranged to transmit one wavelengthof light whilst reflecting another wavelength. For example, the mirrorcan be adapted to transmit RED light and reflect BLUE light. The objectis illuminated with RED light by an appropriate illuminator (not shown)and the calibration target is illuminated with BLUE light. Deactivatingthe illuminators allows the sensor to image only red ambient light. Ingeneral, it is contemplated that a variety of arrangements ofillumination and mirror construction can be used to differentiatebetween light received from the object and light received from thecalibration target.

Based upon the calibration assembly lens L3, the calibration assemblycan be relatively small and integrated into the lens assembly. As shownin FIG. 1, an exemplary calibration assembly 180 in accordance withvarious of the embodiments contemplated herein is mounted along a sideof the main lens barrel. The assembly 180 can include internal orexternal power/data links 182 as appropriate. It should be clear thatthe form factor of the calibration assembly with respect to the lens ishighly variable in accordance with skill in the art. Desirably, thecalibration assembly in this and/or other embodiments herein is attachedand/or removed as an integral part of the overall lens assembly. In anembodiment, the lens employs a conventional mount arrangement, such as aC-mount. The camera body 112 or another component such as an externalprocessor can include an appropriate port for the power/data link 160 sothat the calibration assembly can be removably linked to the body. Inone example, a USB-based connection can be employed to power and/orcontrol the calibration assembly of this or other embodiments herein.

In an example, the distance D1 is approximately 25 mm and angle α isapproximately 7 degrees (and more generally approximately 5-10 degrees).The optical path distance D2 from the calibration assembly lens L3 tothe intersection 312 and D3 from the intersection to the variable lensL2 is approximately 6-12 mm. Likewise the axial spacing D4 of lenses L2and L1 is approximately 5 mm and the distance D5 between the sensor(116) image plane and imager lens L1 is approximately 20 mm. Lens L1define a focal length of approximately 20 mm and liquid lens L2 definesa variable focal length in a range of approximately 200 mm to infinity.Lens L3 defines a focal length of approximately 25 mm. These distancesand/or values are highly variable in alternate embodiments, and shouldbe taken only by way of a non-limiting example.

More generally the optical system can be characterized as follows andwith further reference to the idealized representation of the opticalsystem 300 as shown in FIG. 3A:

For the purposes of this representation, it is assumed that all lenses1A, L2A and L3A are thin and relatively close to each other along thecommon optical axis OAA (direction arrow s) when compared to object 350and the calibrations distances. As such, the optical power of the lensesL1, L2, L3 can be defined respectively as A1, A2 and A3. The distance bis between the calibration target and the optical axis OAA along they-axis perpendicular thereto (y arrow). In this example L1 and L3 arefixed glass lenses and L2 is a liquid lens with variable optical power.The goal is to measure this lens' power. Point (s₂,y₂) on thecalibration focus 356 is imaged (sharp, in focus) on (s₁,y₁) onto thesensor 352.

The calibration target is oriented at an angle on a line (dashed)defined by the equation:y ₂ =a*s ₂ +b  (eq. 1)It is known that:1/s ₁+1/s ₂ =A1+A2+A3  (eq. 2)andy ₁ /s ₁ =y ₂ /s ₂  (eq. 3)thus, combing (eq. 3) into (eq. 1) yields:1/s ₂ =y ₁/(b*s ₁)−a/b  (eq. 4)and combining (eq. 4 into (eq. 2) yields the power for lens L2:A2=A1+A3−1/s ₁ −y ₁/(b*s ₁)+a/b.Note that there exists a linear relationship between the position y₁ onthe sensor 352 where the calibration target is sharply imaged and theoptical power A2 of the lens L2.

With reference briefly to FIGS. 3B and 3C, the ray trace 370 for thesystem 300 is shown for the variable lens L2 at minimal power (i.e.magnification A2 set to zero (0) or approximately zero (0)) and atmaximum power. At zero (0) power (represented by a flat lens (I2)surface 374), the location 340 on the calibration target 330 is in-focusat location 380 on the sensor 116 (FIG. 3B). At maximum power(represented by a convex lens (L2) surface 374), the location 342 on thetarget 330 is in-focus at location 382 on the sensor 116 (FIG. 3C). Therepresentation of FIGS. 3B and 3C is illustrative of a variety ofarrangements and/or positions in which locations along the target arefocused on the sensor.

With reference now to FIG. 4, a lens assembly 400 in accordance with afurther embodiment is shown schematically. Note that any components andparameters in the lens assembly 400 that are identical or similar tothose in the above-described assembly 300 (FIG. 3) are provided withlike reference numbers. As shown, the calibration assembly 410 isaligned along an axis CA1 that intersects with the optical axis OA atpoint 312 in conjunction with the above-described beam splitter 314. Inthis embodiment a point source illuminator 420 (for example adiode-based illuminator) is selectively operated to project a sphericalwave front to the beam splitter 314. The point source 420 is located ata known distance D6 as shown, and can be built into an appropriatestructure on the lens assembly as described above. In general, the pointsource is positioned at a distance of 1/(A1+A2) where A1 is the opticalpower of fixed lens L1 and A2 is the optical power of variable (liquid)lens L2 The beam is passed through the lenses L2 and L1 and thereafterrays 440 pass through one or more conventional micro lenses 450 that canbe located so as to focus the rays 440 on a portion 460 of the sensor116—for example, near an edge of the sensor's field of view whereinterference with the main image is minimized. These micro lenses 450define a basic Shack-Hartmann (wave front) sensor. The portions 460 ofthe sensor 116 exposed by the micro lenses are monitored by the focusprocess 160 when the illuminator 420 is activated. Based upon where on agiven portion 460 (i.e. which pixel(s) in the sensor array) the point ofthe focused beam falls, the shift of that point can be used to determinethe focal distance of the lens assembly using known computations andstored calibration data (170). The variable lens L2 can be adjusted toachieve the focal distance that places the point(s) generated by themicro lens(es) in the appropriate spot on a given portion 460 of thesensor 116.

By way of further illustration reference is made to FIGS. 4A and 4B,which each show the optical relationship between components inaccordance with the embodiment of FIG. 4. It can be assumed that lensesL1 and L2 are thin and mounted at close distance relative to each other.The optical power of the fixed lens L1 and the variable lens L2 are eachdefined as A1 and A2, respectively. ML1 and ML2 are micro lenses withfocal length f. The image sensor IS is located in the focal plane ofeach of these lenses. The axis OML of each micro lens ML1 and ML2 isparallel with the optical axis OAB of the system with an offset distanceh between axes OML and OAB. Although the position of the point source PSis highly variable, for simplicity in this example, the point source PSis positioned at such an object distance, that when the variable lens L2is set at zero optical power (A2=0), the spherical beam from the pointsource PS (via beam-splitting mirror M) is collimated into a planar wavefront by variable lens L2 (FIG. 4A). Micro lenses ML1 and ML2 focus thisbeam of light onto the sensor in two spots B1 and B2 as shown. Whenvarying the optical power A2 of the lens L2, these spots B1, B2 areshifted over a distance d (FIG. 4B). The optical power A2 of thevariable lens L2 can be calculated from this distance d (which is,itself, determined by the pixel location of the spots B1, B2 on thesensor IS) with the following equation:A2=d/(h*f+d*(s ₁ −f))

With reference to FIG. 5, another embodiment of a lens assembly 500 isshown and described. Again, any components and parameters in the lensassembly 500 that are identical or similar to those in theabove-described assembly 300 (FIG. 3) are provided with like referencenumbers. In this embodiment, the calibration assembly 510 uses a smallportion of the lens assembly's field of view (typically along an edgethereof), which is covered with a miniature mirror or prism 520. Themirror resides axially between the variable lens L2 and the object 124.In this embodiment, the mirror/prism 520 is located at an axial (e.g.with reference to OA) distance D7 that places it within the barrel ofthe lens assembly (for example as shown by assembly 180 in FIG. 1). Themirror/prism 520 is angled at approximately 45 degrees with respect tothe optical axis OA so that it reflects light from a small calibrationtarget 530 located at a standoff distance D8 above the mirror/prism 520.The plane of the target 530 is shown perpendicular to a dashed line 540that is, itself, perpendicular to the optical axis OA. The target 530can be separately illuminated or rely upon ambient light. The target canbe any acceptable pattern. In general, the location of projection ontothe sensor 116 and appearance of the pattern will vary depending uponthe current focal distance as provided by the variable lens L2. Storedcalibration data (170) can be used to determine the focal distance basedupon the projection on the sensor.

Based upon the arrangement of components shown in FIG. 5 above, theoptical power A2 of the Lens L2 is computed based upon the equation:A2=A1−1/s ₁−1/s ₂, in which

s1 is the lens-to-sensor distance;

s2 is the distance between the lens and calibration target; and

A1 is the optical power of the lens L1.

It is assumed for the purposes of this relationship that the lenses anddistances between lenses are small compared to the object-to-sensordistance.

It should be clear that the calibration target 530 can be provided as aplurality of calibration targets located at varying, respectivedistances. Additionally, it is expressly contemplated that thatabove-described arrangement in FIG. 5, in which a portion of the fieldof view is redirected to include an image of a calibration target can beapplied in the calibration techniques shown and described with referenceto FIGS. 3 and 4 above. That is, the calibration images produced bythese methods can be projected onto a portion of the sensor's overallfield of view. The calibration image is analyzed within this portiondiscretely (separately) relative to the remaining field of view that isdedicated to analysis of the runtime object.

Reference is made to FIG. 6, which shows a generalized procedure orprocess 600 for determining and controlling focal distance of a lensassembly constructed in accordance with each of the arrangementsdescribed above. The procedure or process can be carried out at camerainitialization, or on a periodic basis during operation. In asymbology-reading application, the calibration process can be carriedout immediately after a successful read of a barcode or other symbol onan object. Where the objects are passed through the imaged scene on aconveyor, the height information of a subsequent object is oftenavailable (after the previous successful read) and thus, the knownheight of the subsequent object can be used to set the new focaldistance for the reading of this object. The period of operation ishighly variable, and the rapid nature of the computations lendthemselves to fairly frequent or continuous calibration if desired. Inparticular, the procedure/process 600 begins, optionally, with an exitfrom runtime acquisition of object images by the vision processor 140 instep 610. In alternate embodiments, the procedure can occur incombination with, or contemporaneous with, runtime operation—for examplein the arrangement of FIG. 5 where a portion of the field of view (notused in runtime image acquisition analysis) is used to analyze thecalibration target 530 or where a dedicated wavelength is used toproject light to the sensor from the calibration assembly. In either,runtime or non-runtime operation, the procedure 600 next operates tofocus process (160) in step 620. Where the integral calibration assemblyincludes illumination, such illuminator(s) is/are operated in step 630while the sensor acquired an image of a predetermined pattern from theintegral calibration target. Using the acquired image of the pattern onall or a portion of the sensor, the procedure 600 uses storedcalibration information and/or data (170) to determine the current focaldistance of the lens assembly in step 640. This determination step caninclude use of a look-up table that maps focal distances to specificimage data related to the calibration target pattern and/or projectedposition (e.g. in the wave front arrangement of FIG. 4) on the sensor.The information 170 can also include conventional equations or formulasthat allow for computation of the specific focal distance based uponmeasured image data from the sensor. For example, in the arrangement ofFIG. 3, where a focal distance falls between two lines, equations tointerpolate a distance between those lines can be employed to achievehigh accuracy.

Having determined the current focal distance in step 640, the procedure600 can decide whether the focal distance is within a predeterminedparameter or range (decision step 650) based upon a programmed valueavailable to the focus process (160). If the focal distance is withinparameters, then the procedure 600 resumes runtime value (if exited), orotherwise enters a state of correct focus in step 660. The procedurethen awaits the next programmed calibration interval and repeats steps610-650. If the focal distance is outside a predetermined range, thenthe procedure controls the variable lens (L2) inn step 670 by exertingappropriate force F (or by other mechanisms) so that its geometry isadjusted to provide the desired focal distance. The control step 670computes the appropriate setting for the lens using appropriateequations and information related to lens adjustment. For example, ifthe focal distance is read as 1 m and 2 m is desired, the focus processinstructs the lens to change the force F by a predetermined amount thatachieves this 2 m setting. If confidence in the reset focal distance isrelatively high, then the procedure 600 can optionally branch to theresume runtime step 660 (via dashed line procedure branch 672).Alternatively, if verification of the new setting is desirable, theprocedure 600 can return to steps 630-650 (via dashed line procedurebranch 674) and determine the new focal distance. This process canrepeat (loop) until decision step 650 determines that the desired focaldistance has been achieved.

It should be clear that the system and method for determining andcontrolling focal distance in a lens assembly having a variable(typically liquid) lens is relatively reliable, uses few complexcomponents and can be run rapidly and repeatedly. This system and methodintegrates relatively well with existing lens arrangements and can bepart of a removable and/or replaceable lens system on a vision systemcamera.

The foregoing has been a detailed description of illustrativeembodiments of the invention. Various modifications and additions can bemade without departing from the spirit and scope of this invention.Features of each of the various embodiments described above may becombined with features of other described embodiments as appropriate inorder to provide a multiplicity of feature combinations in associatednew embodiments. Furthermore, while the foregoing describes a number ofseparate embodiments of the apparatus and method of the presentinvention, what has been described herein is merely illustrative of theapplication of the principles of the present invention. For example, theorientation of calibration assemblies with respect to the optical axisof the lens assembly is highly variable in alternate embodiments and canbe varied based upon, for example packaging concerns. The use ofappropriate optical components to achieve such a form factor shouldclear to those of skill. Likewise, while a basic two-lens assembly isshown and described, more complex lens arrangements can be used inconjunction with one or more of the illustrative calibration assembliesdescribed herein. Likewise patterns on any of the calibration targetsdescribed herein are highly variable as are the positions on the sensorat which such target patterns (or other calibration images) areprojected. Accordingly, this description is meant to be taken only byway of example, and not to otherwise limit the scope of this invention.

What is claimed is:
 1. A system for determining focal distance of a lensassembly comprising: a liquid lens; a calibration assembly integral withthe lens assembly, the calibration assembly including a projectedpattern of light that variably projects upon a camera sensor receivinglight from the lens assembly based upon a focus setting of the liquidlens; and a focus process that determines the focal distance of the lensassembly at the focus setting based upon predetermined calibrationinformation with respect to the projected pattern of light.
 2. Thesystem of claim 1 wherein the liquid lens comprises a membrane-basedliquid lens.
 3. The system of claim 1 wherein the liquid lens comprisesan iso-density type liquid lens.
 4. The system of claim 1 wherein atleast one of an appearance or a position of the projected pattern variesbased upon the focus setting of the liquid lens.
 5. The system of claim1 wherein the calibration assembly is located so as to project thepattern on an axis approximately perpendicular to an optical axis of thelens assembly through a reflecting surface onto the optical axis.
 6. Thesystem of claim 5 wherein the reflecting surface is at least one of aprism or a mirror.
 7. The system of claim 1 wherein the focus setting isvaried by applying force to the liquid lens.
 8. The system of claim 2wherein the focus setting is varied by applying force to a perimeter ofthe membrane-based liquid lens.
 9. The system of claim 2 wherein thefocus setting is varied by electromagnetic actuation.
 10. The system ofclaim 1 wherein the focus process continuously determines and updatesthe focal distance.
 11. The system of claim 1 wherein the focal distanceis determined continuously.
 12. A method for determining focal distanceof a lens assembly including a liquid lens, the method comprising thesteps of: applying force to the liquid lens to provide a focus setting;projecting, with a calibration assembly, a pattern of light thatvariably projects upon a camera sensor receiving light from the lensassembly based upon the focus setting of the liquid lens; anddetermining the focal distance of the lens assembly at the focus settingbased upon predetermined calibration information with respect to thepattern.
 13. The system of claim 12 wherein the liquid lens comprises amembrane-based liquid lens.
 14. The system of claim 12 wherein theliquid lens comprises an iso-density type liquid lens.
 15. The system ofclaim 13 wherein the force is applied to a perimeter of themembrane-based liquid lens.